HP DesignJet L28500 Service Manual and Parts List Manual

Content for HP DesignJet L28500 Service Manual and Parts List Manual:

1. PRINTER SYSTEMS
Electrical system
Substrate path
Ink Delivery System (IDS)
Scan Axis and Carriage
Service Station and waste management
Heating system
Front Panel

2. TROUBLESHOOTING
Troubleshooting the printer
Printer education and training
Firmware update
Troubleshooting system error codes
Performing a service test on a failed assembly
Performing the necessary service calibrations
The printer does not power on
How to read the power switch LEDs
How to read the Formatter LEDs
How to read other LEDs
Voltage check at installation
Troubleshooting substrate jams or printhead crashes
The printer continuously rejects printheads
The cutter does not function
Troubleshooting Carriage shutdowns
How to troubleshoot the 86:01 system error
Troubleshooting the drying and curing heaters
Troubleshooting sensors
Cover Sensors
The Line Sensor
OMAS
How to troubleshoot the 79:04 system error
Vacuum suction much lower at high altitudes
Banding due to ink cartridge replacement while printing
How to interpret the Service Information Pages
How to obtain the printer log and the diagnostics package

3. SYSTEM ERROR CODES
Introduction
System error codes and warnings-explanation
Continuable and non-continuable error codes
01.0:03 – Engine PCA electronics error
01.0:10 – Engine PCA hardware failure
01.1.03 – PrintMech PCA electronics error
01.1.10 – PrintMech PCA hardware failure
01.2:10 – ISS Pre-Driver PCA communication failure
01.3:10 – ISS Pre-Driver PCA communication failure
01.10:10 – PrintMech PCA is faulty
01.11:10 – PrintMech PCA is faulty
02:10 – Mechanical Carriage error
02.1:10 – Problem with the Carriage PCA
03:10 – Power distribution failure
03.10:10 – Extra 24 V PSU failure
05:10 – Formatter communication failure with ISS
05.01:10 – Formatter CPU fan stopped or burnt out
06.03 – Main NVM communication failure
06.10 – Main NVM communication failure
08.04 – The Front Panel watchdog timer has expired
Replace the Formatter – Page 452
08:08 – ASSERT in Front Panel code
08:11 – A Front Panel application has died
11:10 – Connection problem with the Trailing Cable
14.31:10 – Pinch Power regulator V null and no fault
14.32:01 – Pinch Power regulator V null and faulty
14.33:01 – Pinch Power regulator V lower than 140
14.34:01 – Pinch Power regulator V lower than 180
14.35:01 – Pinch Power regulator V higher than Vmax
14.36:11 – Pinch Power regulator V could not be read
14.40:10 – Pinch Power regulator current not null
14.41:10 – Pinch Power regulator current too high
14.42:10 – Pinch Power regulator short-circuit
14.43:11 – Pinch Power Regulator open circuit
14.46:11 – Pinch Power regulator R out of range
14.47:10 – Pinch Power regulator OverTemp
14.48:10 – Pinch Power regulator overvoltage or short-circuit
14.49:10 – Pinch sine-wave converter failure
14.51:10 – Overdrive power regulator V null and no fault
14.52:01 – Overdrive power regulator V null and fault
14.53:01 – Overdrive power regulator V lower than 140
14.54:01 – Overdrive power regulator V lower than 180
14.55:01 – Overdrive power regulator V higher than Vmax
14.56:11 – Overdrive power regulator V could not be read
14.60:10 – Overdrive power regulator current not null
14.61:10 – Overdrive power regulator current too high
14.62:10 – Overdrive power regulator short-circuit
14.63:11 – Overdrive power regulator open circuit
14.66:11 – Overdrive power regulator R out of range
14.67:10 – Overdrive power regulator OverTemp
14.68:10 – Overdrive power regulator overvoltage or short-circuit
14.69:10 – Overdrive sine-wave error
14.71:10 – Curing power regulator V null and no fault
14.72:01 – Curing power regulator V null and fault
14.73:01 – Curing power regulator V lower than 140
14.74:01 – Curing power regulator V lower than 180
14.75:01 – Curing power regulator V higher than Vmax
14.76:11 – Curing power regulator V could not be read
14.80:10 – Curing power regulator current not null
14.81:10 – Curing power regulator current too high
14.82:10 – Curing power regulator short-circuit
14.83:11 – Curing power regulator open circuit
14.84:11 – Curing power regulator Rtotal is nominal1
14.85:11 – Curing power regulator Rtotal is nominal2
14.86:11 – Curing power regulator R out of range
14.87:10 – Curing power regulator OverTemp
14.88:10 – Curing power regulator overvoltage or short-circuit
14.89:10 – Curing sine-wave converter failure
15.01:00 – Drying system warn-up timed out
15.02:00 – Drying system cool-down timed out
15.03:00 – Drying system temperature too high
15.04:00 – Drying system temperature too low
15.05:00 – Problem with the drying system Temperature Sensor
15.06:00 – Temperature error detected
15.08:00 – Heating fans array not connected
15.09:11 – Heating fan fault
15.15:11 – Drying fan short-circuit
15.20:01 – Minimum drying power has been automatically adjusted
15.15:11 – Drying fan short-circuit
16.01:00 – Curing system warn-up timed out
16.02:00 – Curing system cool-down timed out
16.03:00 – Curing system temperature too high
16.04:00 – Curing system temperature too low
16.05:00 – Problem with the curing system Temperature Sensor
16.06:00 – Temperature error detected
16.08:00 – Curing fans array 1 not connected
16.09:00 – Curing fan array 1 fault
16.11:00 – Curing fans array 2 not connected
16.20:11 – IR sensor curing fan not connected
16.21:10 – Curing fan array 2 fault
17.0:11 – PrintMech to Interconnect power cable disconnected
17.1:11 – PrintMech to Interconnect data 1 cable disconnected
17.2:11 – PrintMech to Interconnect data 2 cable disconnected
17.3:11 – Engine PCA to PrintMech black 1 cable disconnected
17.4:11 – Engine PCA to PrintMech blue 2 cable disconnected
21:03 – Service Station electrical current limit
21:13 – Problem with the Service Station
21.2:10 – Problem with the Web Wipe motor
21.3:10 – Electrical problem in the Web Wipe Motor
21.4:03 – Electrical problem in the Web Wipe Motor
21.5:03 – Web Wipe Assembly Drifting
23:10 – Air Pressure System failure
24:03 – Ink Supply Tubes purge failure
24:10 – Ink cartridge broken bag
24:11 – PrintMech PCA to ISS Top cable disconnected
24.1:11 – ISS Top PCA to ISS Bottom PCA cable disconnected
24.02:00 – Top Cover fans disconnected
24.03:00 – Top Cover fans not working
26:14 – A wrong ink cartridge has been detected
26.0:01 – Contact failure with magenta ink cartridge
26.1:01 – Contact failure with yellow ink cartridge
26.2:01 – Contact failure with black ink cartridge
26.3:01 – Contact failure with cyan ink cartridge
26.4:01 – Contact failure with light magenta ink cartridge
26.5:01 – Contact failure with light cyan ink cartridge
27:01 – Calibration failed due to a printhead
27:14 – A wrong printhead has been detected
27:14 – A wrong printhead has been detected
27.2:01 – Calibration failed due to printhead in slot 2
27.3:01 – Calibration failed due to printhead in slot 3
27.4:01 – Calibration failed due to printhead in slot 4
27.5:01 – Calibration failed due to printhead in slot 5
27.6:01 – Calibration failed due to printhead in slot 6
29:01 – Printhead Cleaning Cartridge incorrectly inserted
32:01 – Take-Up Reel disconnected
32:01.1 – Early Take-Up Reel substrate jam
32:01.2 – Take-Up Reel substrate jam
32:01.9 – Take-Up Reel substrate unexpectedly removed
32:02 – Take-Up Reel disconnected at initialization
41:03 – Media-Axis Motor electrical current limit
42:03 – Scan-Axis Motor electrical current limit
42:10 – Electrical fault in the Scan Axis area
42.10:11 – Scan-Axis Motor cooling fan not connected
42.11:10 – Scan-Axis Motor cooling fan fault
43:11 – Vacuum Fan not connected
43.2:11 – Vacuum Fan stopped
43.3:10 – Vacuum Fan overcurrent
43.4:10 – Vacuum Fan low performance
43.11:11 – Vacuum Fan 2 or 3 not connected
43.12:11 – Vacuum Fan 2 or 3 stopped
43.13:10 – Vacuum Fan 2 or 3 overcurrent
43.14:10 – Vacuum Fan 2 or 3 low performance
44:10 – There is a problem with the Aerosol Fan
44:11 – Aerosol Fan not connected
44.2:01 – Waste management switch open
44.3:01 – Waste management cable short-circuited
44.4:01 – Problem in the waste management feedback signal
45:03 – Rewinder servo shutdown
45:10 – Rewinder fault
46:03 – Primer servo shutdown
46:10 – Primer test distance failed
50:14 – Firmware version mismatch
50.1:10 – OMAS communication failure
50.2:10 – OMAS Controller Card communication failure
50.3:11 – Engine PCA to OMAS Controller cable not connected
50.10:11 – TOMAS error
52:01 – A problem with the Drop Detector
52:10 – A problem with the On/Off switch in the Drop Detector
53.1:10 – Media Sensor error
53.1:11 – Media Sensor cable not connected
54:10 – Media Lever Sensor error
55:10 – Line Sensor communication failure
56:01 – Incorrect readings from Substrate Encoder
56:10 – Substrate Encoder calibration failed
58:01 – Color Sensor shutter error
58:10 – Color Sensor failure
58.1:10 – Color Sensor Shutter Actuator failure
58.2:10 – Color Sensor Shutter Deactivator failure
59.1:09 – Two electrical parts have been replaced at the same time
59.2:00 – An unsupported or reused part has been installed
61:10 – Data lost due to I/O timeout
63:05 – The job is reaching the printer too slowly
65:04 – I/O problem though an unknown port
65:04 – I/O problem though an unknown port
77:04 – Embedded Web Server internal software error
78.1:04 – Substrate settings error
78.2:01 – The back tension has been lost
79:03 – Generic firmware error I
79:04 – Generic firmware error II
81:01 – Possible substrate jam
81:03 – Problem with setting the encoder position
82:01 – Substrate jam in the platen area
85:03 – Drive Roller encoder problem
86:01 – Possible substrate jam
87:01 – Problem with the Scan Axis encoder sensor readings
94:01 – Substrate unsuitable for color calibration
94:02 – Color calibration error: inconsistent colors
94:10 – Color Sensor contaminated by aerosol
98:03 – Printhead nozzles out

4. SERVICE TESTS, UTILITIES & CALIBRATIONS
Introduction
Diagnostics – Self Test
Service Tests
Service Tests
Entering the Diagnostics Menu
1. Electrical System
1.1 Electronics Control
1.2 All Fans
1.3 Hard Disk Drive
1.4 Hard Disk Recovery
1.5 File System Check
1.6 IO Information
1.7 Enable I/O Interfaces
1.8 Unit information
1.9 SE 59.2:00 Recovery: Set SN and PN
1.9 SE 59.2:00 Recovery: Set SN and PN
1.10 EEROM reset
2. Substrate Path
2.1 Rewinder System
2.2 Drive Roller
2.3 Substrate Path Sensors
2.4 OMAS Module
2.5 Solve Substrate Jam
3. Ink System
3.1 Air Pressure System
3.2 Check Ink Supplies
3.3 Broken Bag Recovery Menu
3.3.1 Clean Air Tubes
3.3.2 Recover Broken Bag
3.3.3 Refill Ink Tubes
4. Scan Axis
4.1 Scan Axis Test
4.2 Scan Axis Cycles
5. Carriage
5.1 Carriage PCA
5.2 Color Sensor
5.3 Line Sensor Check
6. Service Station
6.1 Shuttle Close Loop
6.2 Web Wipe Motor
6.3 Primer
7. Heating and Curing
7.1 Heating
7.2 Curing
7.3 Heating IR Sensor
7.4 Curing IR Sensor
7.5 Monitoring sine-waves and resistances
8. Covers
8.1 Cover/Switch Sensor
9. Diagnostic Utilities
9.1 Force Normal Boot
9.2 Force Diagnostic Boot
9.3 Report Tests Version
9.4 Enable/Disable Logs
Service Menu
1. Service Tests and Utilities Menu
1.1 Boot Mode
1.1.1 Force Diagnostic Mode
1.1.2 Force Normal Mode
1.2 Electrical System
1.2.1 Set Date and Time
1.2.2 Enable/Disable Firewall
1.2.3. Enable/Disable Logs
1.2.4 Input/Output
1.2.5 Set Serial Number
1.2.6 Sleep Mode
1.2.7 Report Test Version
1.3 Substrate Path
1.3.1 Turn Drive Roller
1.3.2. Enable/Disable OMAS
1.3.3 OMAS Sensor Check
1.4 Ink System
1.4.1 Purge Tubes
1.5 Scan Axis
1.5.1 Force Drop Detection
1.6 Carriage
1.6.1. Color Sensor Shutter Diagnostic
1.6.2 Color Sensor Measurement Test
1.6.3 Color Sensor Check
1.6.4 Test Cutter
1.7 Service Station
1.7.1. Prime Pen X
1.8 Heating and Curing
1.8.1 Heating and Curing Temperature
1.8.2 Enable Heating and Curing
1.9 Show Test Messages
1.10 Force FW Upgrade
1.11 Hard Disk Recovery
2. Image Quality Plots
2.1 Print ALL Plots
2.2 Printhead Alignment
2.2.1 Test Plot
2.2.2 Advanced Test Plot
2.2.3 Automatic Printhead Alignment
2.2.4 Manual PH Alignment
2.2.4.1 Print Pattern
2.2.4.2 Manual Alignment Settings
2.3 Substrate Advance
2.3.1 Print Adjustment Plot
2.3.2 Reset Substrate Advance
2.4 Printhead Health
2.4.1 Print Test Plot
2.4.2 Advanced Test Plot
2.4.3 Only for Escalations
2.4.4 Clean All Printheads
2.4.5 Clean LC-C Printheads
2.4.6 Clean Y-MK Printheads
2.4.7 Clean LM-M Printheads
2.5 Geometry Check
2.6 Scan Axis Check
2.7 Vacuum Check
2.8 Side Registration Check
2.11 Others
3. Ink On Substrate Test
3.1Print Test Plot at 6 passes
3.2 Print Test Plot at 8 passes
3.3 Print Test Plot at 10 passes
3.4 Print Test Plot at 12 passes
4. Reset Life Counters (NEVER DONE BY CUSTOMER)
4.1 Reset Maint. Kit Usage
4.2 Reset Substrate Path
4.3 Reset ISS
4.4 Reset Scan Axis
4.5 Reset Carriage
4.6 Reset Service Station
4.7 Reset Heating & Curing
5. Service Calibrations
5.1 Substrate Path
5.1.1 Substrate Advance Calibration
5.1.2 OMAS calibration
5.1.3 Reset Vacuum Calibration
5.1.4 Rewinder Calibration
5.2 Scan Axis
5.2.1 Scan Axis Calibration
5.2.2 Drop Detector Calibration
5.3 Carriage
5.3.1 Line Sensor Calib
5.3.2 Primer Calibration
5.3.3 Color Sensor Shutter Calibration
5.3.4 Color Sensor Calibration

5. PRINT QUALITY
Initial print quality troubleshooting actions
How to use the image quality plots
2.2.1 Printhead alignment test plot
2.4.1 Printhead health test plot
2.3.2 Print adjustment plot
2.4.2 Advanced printhead health test plot
2.4.3 Plot for escalation only
2.5 Geometry check
2.6 Scan axis check
2.7 Vacuum check
2.8 Misregistration check
3.1 Inks on substrate test
Force drop detection
Troubleshooting non-uniform curing
Substrate advance issues

6. INK SUPPLIES
What are ink supplies?
General information about the ink supplies
General precautions when handling ink supplies
Priming the ink system
When should you replace the ink supplies?
Obtaining ink cartridge and printhead information
Troubleshoot ink cartridge and printhead issues
The front panel recommends replacing or reseating a printhead
Warranty information for ink supplies

7. PARTS AND DIAGRAMS
Printer Support
Front Covers
Top & Back Covers
Electronics Module
Power Cabinet
Right Cover
Left Cover
Right Hand Assemblies
Waste Management System
Left Hand Assemblies
Vacuum Extra
Carriage Assembly
Dryer Assembly
Curing Assemblies
Curing Fans Assembly
Scan-Axis Assemblies
Drive Roller and Media-Axis Motor
Substrate Path Assemblies
Media Input (MI) and Pinchwheel Assembly
Media Entry Assemblies
Take-Up Reel Assembly
Miscellaneous Parts

8. REMOVAL & INSTALLATION
Two contents lists are provided for this chapter to help you to quickly find the service part you want to
replace. The first list is provided in Service part order and the second in Disassembly order.
Service part order
Introduction
Opening the Window
APS Assembly
Belt Assembly
Carriage Assembly with Belt, Pulley, and Tensioner
Carriage Flex Cables
Carriage PCA
Cartridge Tray
Circuit Breakers
Color Sensor Actuator Assembly
Color Sensor Assembly
Curing Fans and Cover
Curing Heaters
Curing Holders
Curing IR Temperature Sensor & Fan
Curing Module
Cutter Assembly
Drive Roller
Drop Detector, Funnel Transmission, Waste Ink Tube
Dryer Grill
Dryer Heater
Dryer IR Temperature Sensor
Dryer Protector
Electronics Enclosure
Electronics Enclosure Extension Cover
Encoder Disc and Sensor
Encoder Strip
Engine PCA
Extra PSU 24 V
Formatter Battery
Formatter PCA
Front Panel
Front Tube Shelf Beam
Hard Disk Drive
Heater Controller Box
Hinge Brakes
Individual Pinchwheel Rollers
Ink Supply Station (ISS)
Ink Supply Station PCAs (Top and Bottom)
Ink Supply Tubes and Trailing Cable
Input Platen
Input Roller
Interconnect PCA
ISS to Cartridge Cables
Left Cover
Left Curing Cover
Left Trim
Line Sensor Assembly
Media-Axis Motor
Media Input Profile
Media Jam Sensor and Carriage Reflector Assembly
Media Lever Linkage
Media Sensor
Oiler
OMAS Cable
OMAS Controller Card
OMAS: Optical Media Advance Sensor
Output Platen
Output Roller
Pinchwheel Assembly
Pinchwheel Cam Arm
Power Box Cover
Power Supply Unit (PSU)
Pre-Driver PCA
Primer Assembly
Primer Valve Cable
Primer Valves
Print Platen
Printhead Cleaning Cartridge Door
Printhead Cleaning Cartridge Door Sensor
PrintMech PCA
Rear Fans
Rear Upper Cover
Rewinder Left-Hand Module
Rewinder Right-Hand Module
Right Connector Cover
Right Cover
Right Curing Cover
Right Trim, Media Lever, and Media Lever Sensor
Scan-Axis Motor
Scan-Axis Motor Fan
Service Station
Take-Up Reel Diverter
Take-Up Reel Left-Hand Module
Take-Up Reel Right-Hand Module
Take-Up Reel Sensor Module
Tension Bar
TOMAS Cable
TOMAS: Temperature Optical Media Advance Sensor
Top Cover
Top Cover Fans
Vacuum Fan
Vacuum Fan Cable
Vacuum Fans Extra
Waste Ink System
Waste Ink System Support
Waste Ink Tube Guide
Web Wipe Assembly
Window
Window Lock Sensor Left
Window Lock Sensor Right

DISASSEMBLY ORDER
Introduction
Opening the Window
Window
Front Tube Shelf Beam
Hinge Brakes
Right Cover
Right Trim, Media Lever, and Media Lever Sensor
Left Cover
Left Trim
Left Curing Cover
Right Curing Cover
Rear Upper Cover
Top Cover
Right Connector Cover
Power Box Cover
Extra PSU 24 V
Pre-Driver PCA
Electronics Enclosure Extension Cover
Heater Controller Box
Window Lock Sensor Left
Window Lock Sensor Right
Top Cover Fans
Rear Fans
Front Panel
Primer Assembly
Primer Valves
Primer Valve Cable
Service Station
Web Wipe Assembly
Vacuum Fan
Vacuum Fan Cable
Vacuum Fans Extra
Waste Ink System
Waste Ink System Support
Waste Ink Tube Guide
Drop Detector, Funnel Transmission, Waste Ink Tube
Ink Supply Tubes and Trailing Cable
ISS to Cartridge Cables
Cutter Assembly
Ink Supply Station (ISS)
Ink Supply Station PCAs (Top and Bottom)
APS Assembly
Encoder Strip
Carriage PCA
Carriage Flex Cables
Oiler
Carriage Assembly with Belt, Pulley, and Tensioner
Media Jam Sensor and Carriage Reflector Assembly
Belt Assembly
Scan-Axis Motor
Scan-Axis Motor Fan
Media-Axis Motor
OMAS: Optical Media Advance Sensor
TOMAS: Temperature Optical Media Advance Sensor
TOMAS Cable
Interconnect PCA
OMAS Controller Card
OMAS Cable
Engine PCA
Formatter PCA
Hard Disk Drive
Power Supply Unit (PSU)
Formatter Battery
Circuit Breakers
PrintMech PCA
Electronics Enclosure
Line Sensor Assembly
Color Sensor Assembly
Color Sensor Actuator Assembly
Dryer Grill
Dryer IR Temperature Sensor
Dryer Protector
Dryer Heater
Curing Fans and Cover
Curing IR Temperature Sensor & Fan
Curing Module
Curing Heaters
Output Platen
Curing Holders
Print Platen
Cartridge Tray
Input Roller
Media Input Profile
Input Platen
Output Roller
Printhead Cleaning Cartridge Door
Printhead Cleaning Cartridge Door Sensor
Media Sensor
Encoder Disc and Sensor
Media Lever Linkage
Pinchwheel Cam Arm
Pinchwheel Assembly
Individual Pinchwheel Rollers
Drive Roller
Rewinder Left-Hand Module
Take-Up Reel Left-Hand Module
Rewinder Right-Hand Module
Take-Up Reel Right-Hand Module
Take-Up Reel Diverter
Take-Up Reel Sensor Module
Tension Bar

9. PREVENTIVE MAINTENANCE
Moisture on the printer
Belt swelling
Clean the printer
Lubricate the Platen Rollers
Clean and lubricate the Carriage Rail
Scheduled maintenance
Level of printer usage
Adjust for an uneven floor

10. MOVE, STORE, OR REPACK THE PRINTER
Move or store the printer
Repack the printer

11. SAFETY PRECAUTIONS
General safety guidelines
Electrical shock hazard
Heat hazard
Fire hazard
Mechanical hazard
Scan Axis Encoder Strip hazard
Burn hazard (heating and curing)
Lifting and handling
Warning labels